Composite part compaction device

ABSTRACT

Systems and methods are provided for compacting laminates. One embodiment is a method for compacting a laminate onto a surface of a forming tool. The method includes placing the laminate onto the forming tool, disposing a compaction device over the laminate, gripping the compaction device to the forming tool, compacting the laminate with a pressure foot of the compaction device, and removing the compaction device from the forming tool.

RELATED APPLICATIONS

This patent application is a division of U.S. patent application Ser.No. 16/176,257, filed on Oct. 31, 2018 issued as U.S. Pat. No.11,220,071B2 on Jan. 11, 2022.

FIELD

The disclosure relates to the field of composite materials, and inparticular, to fabrication of composite parts.

BACKGROUND

Composite parts, such as Carbon Fiber Reinforced Polymer (CFRP) parts,may be laid-up as a laminate of constituent materials which arecompacted and hardened (e.g., cured) in order to provide strength.Current compaction techniques involve applying a laminate to a mandrel,placing a vacuum bag over the laminate and the mandrel, sealing thevacuum bag in place, and applying atmospheric pressure that presses thevacuum bag onto the laminate. Sealing the vacuum bag in place is atime-consuming and labor-intensive process.

Therefore, it would be desirable to have a method and apparatus thattake into account at least some of the issues discussed above, as wellas other possible issues.

SUMMARY

Embodiments described herein provide for handheld pneumatic and/orelectromagnetic devices which are capable of compacting small laminatessuch as details, without the use of a vacuum bag. For example,embodiments described herein may grip a mandrel or other forming toolvia the application of magnetic force, and may shape a laminate onto themandrel by applying pneumatic pressure to the laminate while maintainingthe grip. One embodiment is a method for compacting a laminate onto asurface of a forming tool. The method includes placing the laminate ontothe forming tool, disposing a compaction device over the laminate,gripping the compaction device to the forming tool, compacting thelaminate with a pressure foot of the compaction device, and removing thecompaction device from the forming tool.

A further embodiment is a non-transitory computer readable mediumembodying programmed instructions which, when executed by a processor,are operable for performing a method for compacting a laminate onto asurface of a forming tool. The method includes placing the laminate ontothe forming tool, disposing a compaction device over the laminate,gripping the compaction device to the forming tool, compacting thelaminate with a pressure foot of the compaction device, and removing thecompaction device from the forming tool.

A further embodiment is an apparatus for compacting a laminate onto asurface of a forming tool. The apparatus includes a body that houses anactuatable ram that applies compressive forces, a pressure footmechanically coupled with the ram and that includes a flexible basedimensioned to cover the laminate while applying compressive forces tothe laminate, a gripping device that controllably applies grippingforces between the apparatus and the forming tool, and a controller thatmaintains a static equilibrium between the gripping forces and thecompressive forces.

Yet another embodiment is a method for laying up a composite preform.The method includes placing a laminate comprising at least one ply offiber reinforced material onto a surface of a forming tool, compactingthe laminate to the forming tool by controllably applying compactionforces to the laminate while maintaining gripping forces between acompaction device and the forming tool, laying up at least one ply atopthe compacted plies at the forming tool, and repeating the steps ofcompacting and placing.

Other illustrative embodiments (e.g., methods and computer-readablemedia relating to the foregoing embodiments) may be described below. Thefeatures, functions, and advantages that have been discussed can beachieved independently in various embodiments or may be combined in yetother embodiments further details of which can be seen with reference tothe following description and drawings.

DESCRIPTION OF THE DRAWINGS

Some embodiments of the present disclosure are now described, by way ofexample only, and with reference to the accompanying drawings. The samereference number represents the same element or the same type of elementon all drawings.

FIG. 1 is a perspective view of a compaction device in an illustrativeembodiment.

FIG. 2 is a further perspective view of a compaction device in anillustrative embodiment.

FIG. 3 is an exploded view of a compaction device in an illustrativeembodiment.

FIG. 4 is a flowchart illustrating a method for operating a compactiondevice to compact a laminate in an illustrative embodiment.

FIGS. 5-11 are side views illustrating a compaction device operating ona laminate in an illustrative embodiment

FIG. 12 is a flowchart illustrating a method for operating a compactiondevice to compact a laminate in an illustrative embodiment.

FIG. 13 is a block diagram of a compaction device in an illustrativeembodiment.

FIG. 14 is a flow diagram of aircraft production and service methodologyin an illustrative embodiment.

FIG. 15 is a block diagram of an aircraft in an illustrative embodiment.

DESCRIPTION

The figures and the following description provide specific illustrativeembodiments of the disclosure. It will thus be appreciated that thoseskilled in the art will be able to devise various arrangements that,although not explicitly described or shown herein, embody the principlesof the disclosure and are included within the scope of the disclosure.Furthermore, any examples described herein are intended to aid inunderstanding the principles of the disclosure, and are to be construedas being without limitation to such specifically recited examples andconditions. As a result, the disclosure is not limited to the specificembodiments or examples described below, but by the claims and theirequivalents.

Composite parts, such as Carbon Fiber Reinforced Polymer (CFRP) parts,are initially laid-up in multiple layers that together are referred toas a preform or laminate. Individual fibers within each layer of thepreform are aligned parallel with each other, but different layers mayexhibit different fiber orientations in order to increase the strengthof the resulting composite along different dimensions. The preform mayinclude a viscous resin that solidifies in order to harden the preforminto a composite part (e.g., for use in an aircraft). Carbon fiber thathas been impregnated with an uncured thermoset resin or a thermoplasticresin is referred to as “prepreg.” Other types of carbon fiber include“dry fiber” which has not been impregnated with thermoset resin but mayinclude a tackifier or binder. Dry fiber may be infused with resin priorto curing. For thermoset resins, the hardening is a one-way processreferred to as curing, while for thermoplastic resins, the resin mayreach a viscous form if it is re-heated.

FIG. 1 is a perspective view of a compaction device 100 in anillustrative embodiment. Compaction device 100 comprises any system,device, or component operable to grip a forming tool and applycompaction pressure to a laminate while the grip is maintained. In thisembodiment, compaction device 100 comprises body 110 and base 120. Base120 includes lower frame 128, from which prongs 122 extend.Electromagnets 124 are mounted to prongs 122 via bearings 126 in orderto enable electromagnets 124 to swivel or rotate in order to align withsurface features (e.g., surfaces oriented at a constant angle) on aforming tool. In further embodiments, bearings 126 may enable swivelingof electromagnets 124 along multiple axes. Electromagnets 124 may beturned on or off in order to rapidly apply and/or remove gripping forcesbetween compaction device 100 and a forming tool. This enables rapidsecurement of compaction device 100 to the forming tool, as well asrapid removal, which reduces time spent preparing to compact a laminate.Such features provide the technical benefit of reduced labor,particularly when compacting multiple small laminates such as details.While electromagnets 124 are illustrated in this embodiment, in furtherembodiments other gripping devices may be utilized such as clamps,suction cups, adhesive pads, etc.

Body 110 houses handles 112 which enable a technician to hold compactiondevice 100 against the forming tool, and, further includes electricalport 132 for receiving electrical power, pneumatic port 134 forreceiving pressurized gas, and switch 142 for activating electromagnets124. Light 154 indicates when electromagnets 124 are activated. Body 110also includes switch 144 for driving a ram, piston, (or any othersuitable component) internal to compaction device 100 that appliescompressive forces to a laminate via a pressure foot. Dial 152 controlsan amount of pressure applied by the ram, in order to ensure that forceapplied by the piston does not overcome gripping forces supplied by theelectromagnets 124. The ram drives a pressure foot (e.g., pressure foot200 of FIG. 2 ) to compact a laminate placed on the forming tool. Inthis embodiment, the ram is driven by pneumatic pressure. However, infurther embodiments, the ram may be driven in response to hydraulicpressure, an electrical motor, etc. Body 110 also includes wire covers116, which are disposed between prongs 122. Furthermore, body 110maintains a static equilibrium between the gripping forces and thecompressive forces discussed above.

FIG. 2 illustrates a further perspective view of compaction device 100in an illustrative embodiment, and corresponds with view arrows 2 ofFIG. 1 . FIG. 2 illustrates pressure foot 200, which is driven against alaminate in order to compact the laminate. Pressure foot 200 comprisesany suitable flexible (e.g., elastic or deformable) material capable ofconforming to one or more surface geometries on a forming tool. In orderto facilitate compaction of a laminate against a variety of surfacegeometries, pressure foot 200 may be made from a stretchable material,such as a rubber or rubberized plastic. In this embodiment, pressurefoot 200 also includes an indentation 210. Indentation 210 provides atechnical benefit by facilitating flexion of pressure foot 200 duringcompaction processes.

FIG. 3 is an exploded view of compaction device 100 in an illustrativeembodiment. FIG. 3 illustrates that base 120 is secured to body 110 viafasteners 310 (e.g., screws, bolts, etc.). FIG. 3 further illustratesthat base 120 includes actuator 340. Actuator 340 (e.g., a pneumaticcylinder) drives ram 350 against plate 330. Plate 330 is interposedbetween the shock absorbers 320 and the ram 350, and is thereforecoupled via shock absorbers 320 with pressure foot 200. Shock absorbers320 are therefore mechanically coupled with pressure foot 200.

In this arrangement, because ram 350 is mechanically coupled withpressure foot 200, actuation of ram 350 drives pressure foot 200.Specifically, actuating the ram 350 drives plate 330 downward, whichcompresses the shock absorbers 320 that are mechanically coupled withthe pressure foot 200 and that distribute load across the pressure foot200. In embodiments where a surface of the forming tool is angled,driving of the ram 350 against plate 330 may adjust an angle of plate330 (i.e., because shock absorbers 320 at different heights along thesurface of the forming tool apply different amounts of force in responseto forces from ram 350). For example, in FIG. 3 plate 330 is tilted atan angle θ due to forces applied via shock absorbers 320. Thisarrangement also provides a technical benefit by distributing forcesapplied by ram 350 across the area of pressure foot 200, which helps toensure that forces are applied evenly to a laminate, even in situationswhere the laminate conforms to a complex contour. In this embodiment,ram 350 is driven by pneumatic pressure. This means that pressure foot200 is driven in response to pneumatic pressure applied to thecompaction device 100.

Illustrative details of the operation of compaction device 100 will bediscussed with regard to FIG. 4 . Assume, for this embodiment, that atechnician has laid-up a laminate, and wishes to place the laminate ontoa forming tool for compaction. Further assume that compaction device 100has been coupled with a pressure reservoir supplying pneumatic pressure,and with an electrical power source.

FIG. 4 is a flowchart illustrating a method 400 for operating acompaction device to compact a laminate in an illustrative embodiment.The steps of method 400 are described with reference to compactiondevice 100 of FIG. 1 , but those skilled in the art will appreciate thatmethod 400 may be performed in other systems. The steps of theflowcharts described herein are not all inclusive and may include othersteps not shown. The steps described herein may also be performed in analternative order.

In step 402, the laminate is placed onto the forming tool. For example,as shown in FIG. 5 (which is a side view illustrated by view arrows 5 ofFIG. 1 ), a laminate 520 may be placed over a forming tool 510 having asurface feature 512.

In step 404, compaction device 100 is placed over the laminate 520, forexample such that pressure foot 200 covers the laminate 520. In FIG. 6 ,compaction device 100 is moved in direction 600 while pressure foot 200is aligned to completely cover laminate 520. Thus, a perimeter 530 ofpressure foot 200 may be dimensioned to equal or exceed a perimeter 540of laminate 520. This enables pressure foot 200 to compact the entiretyof laminate 520 at once.

In step 406, switch 142 is activated, which supplies power toelectromagnets 124. The electromagnets grip the compaction device 100 toforming tool 510 because forming tool 510 is magnetic (e.g., because itis made of steel or invar), resulting in an attractive force 700 betweenelectromagnets 124 and forming tool 510, as shown in FIG. 7 . With agrip applied by electromagnets 124, compaction device 100 remains stableover laminate 520. In further embodiments, the electromagnets may belocated within the forming tool 510 itself, and be activated via aswitch at the forming tool 510. In such an embodiment, electromagnets124 may be replaced with materials that respond to magnetic forces, suchas steel. In a further embodiment, gripping the compaction device 100 tothe forming tool 510 may include activating electromagnets within theforming tool 510 that draw the compaction device 100 into contact withthe forming tool 510.

In step 408, laminate 520 is compacted via pressure foot 200, which ismade of a flexible material. FIGS. 8-9 illustrate the progress ofpressure foot 200 as compaction device 100 activates. For example, anoperator of compaction device 100 may activate switch 144, whichprovides pneumatic pressure to ram 350 via actuator 340. This causes ram350 to displace along direction 800, as shown in FIG. 8 , drivingpressure foot 200 against laminate 520 and therefore compacting laminate520. In FIG. 9 , ram 350 has continued to extend in direction 800, andpressure foot 200 has deformed around laminate 520, resulting incompaction forces being evenly applied to laminate 520 by pressure foot200. During this process, forces applied by the pressure foot 200 areequal to or less than gripping forces supplied by the electromagnets124. The compaction forces are applied evenly even though laminate 520bends due to the surface feature 512 underneath it. This is a technicalbenefit caused by the flexibility of pressure foot 200.

Compaction device 100 may be held or left in this compaction mode forany suitable length of time, such as for thirty seconds, for half anhour, etc. Eventually, compaction has completed. Switch 142 isdeactivated, turning off electromagnets 124 and eliminating attractiveforce 700, as shown in FIG. 10 . Compaction device 100 may then beremoved in step 410 by lifting off of forming tool 510 in direction1100, and flipping the switch 144. Flipping the switch 144 may reset ram350 to an original position by moving ram 350 in direction 1110 of FIG.11 , or may halt application of pneumatic force to ram 350, whichenables shock absorbers 320 to return ram 350 to a resting position. Asshown in FIG. 11 , laminate 520 is now compacted, ensuring that laminate520 will exhibit a desired level of strength when it is hardened.

The operations discussed above may be repeated multiple times as thelaminate 520 is built up with additional layers, and this may beespecially valuable for laminates that exhibit complex contours. In suchembodiments, compaction may be performed iteratively, each time a numberof plies is added to the laminate during layup.

FIG. 12 illustrates a method 1200 for laying up a composite preform. Themethod includes placing a laminate comprising at least one ply of fiberreinforced material (e.g., ten plies) onto a surface of a forming toolin step 1202. In step 1204, the method includes compacting the laminateto the forming tool by controllably applying gripping forces between acompaction device and the forming tool while at atmospheric pressure(i.e., without the use of a vacuum bag). Step 1206 includes laying up atleast one ply (e.g., a next ten plies) atop the compacted plies at theforming tool, and step 1208 includes repeating the steps of compactingand placing. Step 1208 may be performed any suitable number of times,depending on the number of layers in the laminate.

EXAMPLES

In the following examples, additional processes, systems, and methodsare described in the context of a compaction device for laminates.

FIG. 13 is a block diagram of a compaction device 1300 in anillustrative embodiment. According to FIG. 13 , compaction device 1300is poised over laminate 1360, which has been placed onto surface feature1352 of forming tool 1350. Compaction device 1300 includes base 1320,having electromagnets 1324 which magnetically couple with forming tool1350 at locations not covered by laminate 1360. Base 1320 also includespressure foot 1330, shock absorbers 1332, and plate 1334. Thesecomponents are driven by ram 1336, which is driven by actuator 1338powered via pneumatic port 1326. As discussed above, while pneumaticpressure systems are described herein, in further embodiments anysuitable system may be utilized for driving ram 350. Body 1310 includeshandles 1312, pneumatic port 1326, and electrical port 1328. Pneumaticport 1326 powers the actuator 1338, and electrical port 1328 powers theelectromagnets 1324. Magnet switch 1394 controls delivery of power viaelectrical port 1328, and pneumatic switch 1322 controls delivery ofpneumatic pressure to actuator 1338. Controller 1370 may automaticallycontrol the operations of the switches, ports, actuators, etc. describedherein. For example, controller 1370 may maintain a static equilibriumbetween gripping forces and compressive forces to ensure that compactionof the laminate does not push compaction device 1300 off of forming tool1350. Controller 1370 may further control the compaction forces bycontrolling an amount of force applied by ram 1336 to pressure foot1330, which contacts the laminate 1360. For example, this may beperformed to ensure that compaction forces are less than or equal togripping forces. Controller 1370 may comprise hardware processorimplementing instructions in memory, dedicated hardware, etc.

Referring more particularly to the drawings, embodiments of thedisclosure may be described in the context of aircraft manufacturing andservice in method 1400 as shown in FIG. 14 and an aircraft 1402 as shownin FIG. 15 . During pre-production, method 1400 may includespecification and design 1404 of the aircraft 1402 and materialprocurement 1406. During production, component and subassemblymanufacturing 1408 and system integration 1410 of the aircraft 1402takes place. Thereafter, the aircraft 1402 may go through certificationand delivery 1412 in order to be placed in service 1414. While inservice by a customer, the aircraft 1402 is scheduled for routine workin maintenance and service 1416 (which may also include modification,reconfiguration, refurbishment, and so on). Apparatus and methodsembodied herein may be employed during any one or more suitable stagesof the production and service described in method 1400 (e.g.,specification and design 1404, material procurement 1406, component andsubassembly manufacturing 1408, system integration 1410, certificationand delivery 1412, service 1414, maintenance and service 1416) and/orany suitable component of aircraft 1402 (e.g., airframe 1418, systems1420, interior 1422, propulsion system 1424, electrical system 1426,hydraulic system 1428, environmental 1430).

Each of the processes of method 1400 may be performed or carried out bya system integrator, a third party, and/or an operator (e.g., acustomer). For the purposes of this description, a system integrator mayinclude without limitation any number of aircraft manufacturers andmajor-system subcontractors; a third party may include withoutlimitation any number of vendors, subcontractors, and suppliers; and anoperator may be an airline, leasing company, military entity, serviceorganization, and so on.

As shown in FIG. 15 , the aircraft 1402 produced by method 1400 mayinclude an airframe 1418 with a plurality of systems 1420 and aninterior 1422. Examples of systems 1420 include one or more of apropulsion system 1424, an electrical system 1426, a hydraulic system1428, and an environmental system 1430. Any number of other systems maybe included. Although an aerospace example is shown, the principles ofthe invention may be applied to other industries, such as the automotiveindustry.

As already mentioned above, apparatus and methods embodied herein may beemployed during any one or more of the stages of the production andservice described in method 1400. For example, components orsubassemblies corresponding to component and subassembly manufacturing1408 may be fabricated or manufactured in a manner similar to componentsor subassemblies produced while the aircraft 1402 is in service. Also,one or more apparatus embodiments, method embodiments, or a combinationthereof may be utilized during the subassembly manufacturing 1408 andsystem integration 1410, for example, by substantially expeditingassembly of or reducing the cost of an aircraft 1402. Similarly, one ormore of apparatus embodiments, method embodiments, or a combinationthereof may be utilized while the aircraft 1402 is in service, forexample and without limitation during the maintenance and service 1416.For example, the techniques and systems described herein may be used formaterial procurement 1406, component and subassembly manufacturing 1408,system integration 1410, service 1414, and/or maintenance and service1416, and/or may be used for airframe 1418 and/or interior 1422. Thesetechniques and systems may even be utilized for systems 1420, including,for example, propulsion system 1424, electrical system 1426, hydraulic1428, and/or environmental system 1430.

In one embodiment, a part comprises a portion of airframe 1418, and ismanufactured during component and subassembly manufacturing 1408. Thepart may then be assembled into an aircraft in system integration 1410,and then be utilized in service 1414 until wear renders the partunusable. Then, in maintenance and service 1416, the part may bediscarded and replaced with a newly manufactured part. Inventivecomponents and methods may be utilized throughout component andsubassembly manufacturing 1408 in order to manufacture new parts.

Any of the various control elements (e.g., electrical or electroniccomponents) shown in the figures or described herein may be implementedas hardware, a processor implementing software, a processor implementingfirmware, or some combination of these. For example, an element may beimplemented as dedicated hardware. Dedicated hardware elements may bereferred to as “processors”, “controllers”, or some similar terminology.When provided by a processor, the functions may be provided by a singlededicated processor, by a single shared processor, or by a plurality ofindividual processors, some of which may be shared. Moreover, explicituse of the term “processor” or “controller” should not be construed torefer exclusively to hardware capable of executing software, and mayimplicitly include, without limitation, digital signal processor (DSP)hardware, a network processor, application specific integrated circuit(ASIC) or other circuitry, field programmable gate array (FPGA), readonly memory (ROM) for storing software, random access memory (RAM),non-volatile storage, logic, or some other physical hardware componentor module.

Also, a control element may be implemented as instructions executable bya processor or a computer to perform the functions of the element. Someexamples of instructions are software, program code, and firmware. Theinstructions are operational when executed by the processor to directthe processor to perform the functions of the element. The instructionsmay be stored on storage devices that are readable by the processor.Some examples of the storage devices are digital or solid-statememories, magnetic storage media such as a magnetic disks and magnetictapes, hard drives, or optically readable digital data storage media.

Although specific embodiments are described herein, the scope of thedisclosure is not limited to those specific embodiments. The scope ofthe disclosure is defined by the following claims and any equivalentsthereof.

What is claimed is:
 1. An apparatus for compacting a laminate onto asurface of a forming tool, the apparatus comprising: a body that housesan actuatable ram that applies compressive forces to the laminate; apressure foot mechanically coupled with the ram that includes a flexiblematerial dimensioned to cover the laminate while applying thecompressive forces to the laminate; a gripping device, attached to thebody at a position external to the ram and external to dimensions of thepressure foot, wherein the gripping device controllably applies grippingforces between the apparatus and the forming tool, wherein the grippingforces are opposed to the compressive forces, and wherein the grippingdevice comprises electromagnets that secure the body to the formingtool; and a controller that maintains a static equilibrium between thegripping forces and the compressive forces by controlling the grippingforces and the compressive forces independently.
 2. The apparatus ofclaim 1 wherein: the electromagnets are rotatably secured to the bodyand facilitate contact with the forming tool.
 3. The apparatus of claim1 wherein: the forming tool comprises electromagnets coupled with thegripping device that secure the body to the forming tool.
 4. Theapparatus of claim 1 further comprising: shock absorbers that aremechanically coupled with the pressure foot.
 5. The apparatus of claim 4further comprising: a plate that is interposed between the shockabsorbers and the ram.
 6. The apparatus of claim 1 wherein: the pressurefoot includes an indentation configured to facilitate flexion of thepressure foot.
 7. The apparatus of claim 1 wherein: the gripping deviceis configured to grip directly to a surface of the forming tool prior toinitiating compaction of the laminate.
 8. The apparatus of claim 1wherein: the pressure foot is configured to compact the laminate whilethe gripping device remains activated, and is further configured tooperate independently of the gripping device.
 9. The apparatus of claim1 further comprising: handles that are housed at the body and areconfigured for holding by a technician.
 10. The apparatus of claim 1further comprising: a pneumatic port for receiving pressurized gas tooperate the ram.
 11. The apparatus of claim 1 wherein: the pressure footis configured to distribute forces applied by the ram.
 12. The apparatusof claim 1 wherein: the flexible material is selected from the groupconsisting of: rubber and rubberized plastic.
 13. Fabricating a portionof an aircraft using the apparatus of claim
 1. 14. The apparatus ofclaim 1 wherein the ram and the pressure foot are actuatable independentof the gripping device under control of the controller.
 15. An apparatuscomprising a compaction device for a laminate, comprising: a pressurefoot configured and dimensioned to align over, and cover, a laminate ata forming tool, and configured to initiate compaction of the laminate bycontrollably applying compressive forces to the laminate; andelectromagnets, positioned external to dimensions of the pressure foot,that are configured to rotate into alignment with a surface of theforming tool, and configured to controllably generate gripping forcesbetween the apparatus and the forming tool to grip directly to thesurface of the forming tool prior to initiating compaction of thelaminate; wherein the pressure foot is configured to compact thelaminate while the electromagnets remain activated, and configured to beoperated independently of the electromagnets.
 16. Fabricating a portionof an aircraft using the apparatus of claim
 15. 17. The apparatus ofclaim 15 further comprising: a pneumatic ram configured to applycompression forces in opposition to gripping forces between theelectromagnets and the surface of the forming tool; shock absorbers thatare mechanically coupled with the pressure foot; and a plate that isinterposed between the ram and shock absorbers.
 18. The apparatus ofclaim 15 wherein: the pressure foot comprises a flexible materialselected from the group consisting of: rubber and rubberized plastic.19. An apparatus for compacting a laminate onto a surface of a formingtool, the apparatus comprising: a body; a pneumatic ram, housed withinthe body, that applies compressive forces to the laminate onto thesurface of the forming tool; a pressure foot mechanically coupled withthe pneumatic ram, between the pneumatic ram and the laminate, whereinthe pressure foot comprises a flexible material dimensioned to cover thelaminate while the pneumatic ram applies the compressive forces to thelaminate; electromagnets, rotatably attached to the body at a positionexternal to the ram and external to dimensions of the pressure foot,wherein the electromagnets controllably apply gripping forces betweenthe apparatus and the forming tool, wherein the rotatable electromagnetsare configured to be positioned such that the gripping forces secure theapparatus to the forming tool while the pneumatic ram independentlyimparts compressive forces; and a controller that independently controlsthe gripping forces of the electromagnets and the compressive forces ofthe pneumatic ram to assure that the gripping forces are equal to orgreater than the compressive forces.